Process for optimising the position of refrigerator air guides in order to achieve increased energy efficiency of the refrigerator

ABSTRACT

The present disclosure describes a method for configuring an open display refrigerator, the method comprises: measuring an initial temperature difference between the warmest temperature recorded by an array of temperature sensors and the coldest temperature recorded by the array of temperature sensors; coupling an air guide to at least one shelf; adjusting the distance between the air guide and the edge of the shelf for the at least one shelf; measuring a final temperature difference associated with the distance, the final temperature difference being the temperature difference between the warmest temperature recorded by the array of temperature sensors and the coldest temperature recorded by the array of temperatures sensors after coupling an air guide to the at least one shelf; selecting a distance from the plurality of distances that gives rise to at least a threshold temperature difference, or selecting the distance from the plurality of distances wherein the difference between the initial temperature difference and the associated final temperature difference is greatest.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/526,723, entitled “Process for Optimising the Position ofRefrigerator Air Guides in Order to Achieve Increased Energy Efficiencyof the Refrigerator”, filed on Nov. 15, 2021, which is a continuation ofInternational Patent Application No. PCT/GB2020/051182, entitled“Refrigerators” and filed on May 14, 2020, the entire contents of eachof which are hereby incorporated by reference. International PatentApplication No. PCT/GB2020/051182 claims priority to G.B. ApplicationNo. 1906935.0, entitled “Process for Optimising the Position ofRefrigerator Air Guides in Order to Achieve Increased Energy Efficiencyof the Refrigerator” and filed on May 16, 2019.

FIELD

This invention relates to methods of modifying open displayrefrigerators.

BACKGROUND

Open display refrigerators are commonly used in retail environments,such as supermarkets, to store and display products, such as meat anddairy products, which must be kept at lower than ambient temperatures.The open front of such a refrigerator makes it easy for customers toview the products being displayed and to retrieve products they wish topurchase from the refrigerator.

This type of refrigerator has an air curtain, which is established byblowing cold air across the front of the refrigerator. The air curtainissues from an air outlet at the top of the refrigerator towards an airinlet at the bottom of the refrigerator. The air inlet recovers air fromthe air curtain and recirculates it to the air outlet via a cooling heatexchanger and fan.

Generally, it is intended that the air curtain follows a broadly linearpath from the air outlet to the air inlet thereby preventing cold air inthe refrigerator from mixing with warm air exterior to the refrigerator.However, such an air curtain is rather inefficient, in particularbecause the air curtain tends to spill out from the bottom of therefrigerator and warm air from the exterior becomes entrained into theair curtain. To ameliorate this problem of inefficiency, air guidesfixed on the front edge of shelves in the refrigerator can be used tohelp constrain the air curtain within a desired region.

To work effectively, the air guides need to be in reasonably goodalignment with an outer edge of the air curtain. In some refrigeratordesigns, for example those having a deep air outlet, this can result inthere being a large gap between the front edge of the shelves and theair guides. If the air guide protrudes too far from the edge of theshelf, this can prevent shoppers from viewing produce on a shelf sitedbelow the air guide.

SUMMARY

In accordance with a first aspect of the invention, there is provided amethod for configuring an open display refrigerator, wherein the opendisplay refrigerator comprises a refrigerated storage space and at leastone shelf in the interior of the open display refrigerator, air in therefrigerated storage space being separated from air exterior to the opendisplay refrigerator by an air curtain established by a fan which blowsair towards an air outlet, air in the air curtain being recovered by anair inlet which recirculates the air from the air curtain into an airduct coupled to the air outlet and wherein the method comprises: a)providing an array of temperature sensors within the interior of theopen display refrigerator; b) measuring an initial temperaturedifference between the warmest temperature recorded by the array oftemperature sensors and the coldest temperature recorded by the array oftemperature sensors; c) coupling an air guide to an edge of the at leastone shelf distal to a rear wall of the refrigerated storage space at astart point; d) adjusting the distance between the air guide and theedge of the shelf for the at least one shelf; e) measuring a finaltemperature difference associated with the distance, the finaltemperature difference being the temperature difference between thewarmest temperature recorded by the array of temperature sensors and thecoldest temperature recorded by the array of temperatures sensors aftercoupling an air guide to the at least one shelf; f) repeating steps (d)and (e) for a plurality of distances at discrete intervals; g) selectinga distance from the plurality of distances that gives rise to at least athreshold temperature difference, or selecting the distance from theplurality of distances wherein the difference between the initialtemperature difference and the associated final temperature differenceis greatest.

The temperature difference may be measured by placing numerousjelly-bricks (examples of jelly-bricks known in the art are Tylose packsor M-Packs) on the shelves of the refrigerator. The jelly-bricks areused to emulate the items in a refrigerator, in that the refrigeratorneeds to work to cool down the jelly-bricks and to maintain them at alower than ambient temperature. Each jelly-brick may have its owntemperature sensor or probe, which together may make up the array oftemperature sensors or probes. In this way, the temperature at differentpoints of the refrigerator can be tracked. Alternatively, a sub-set ofthe jelly-bricks may have their own temperature sensor or probe. Thissub-set of jelly-bricks with temperature sensors may be located atregular intervals on all of the shelves, or there may be clusters ofprobes near different features of the refrigerator, such as the airoutlet, air inlet or above a cooling unit or heat exchanger of therefrigerator (as ice is more likely to form above the cooling unit orheat exchanger if the refrigerator is set up sub-optimally). Othervariables, such as humidity may also be measured by additional probesassociated with each jelly-brick or a sub-set of the jelly-bricks. Asthe location of the warmest jelly-brick and the location of the coolestjelly-brick may change with the addition of the air guide and/oradjustments made to the air guide, the difference between thetemperature of the warmest jelly-brick and the temperature of thecoolest jelly-brick is measured, so that the overall effect on therefrigerator temperature can be monitored. In some embodiments,stand-alone thermometers may be used instead of an array of temperatureprobes and the temperatures may be collected individually from differentlocations in the refrigerator. Alternatively, a user with an infraredthermometer may measure the temperatures of the visible jelly-bricks andrecord the location and temperatures of the hottest and the coldestjelly-bricks.

The threshold temperature difference may be any meaningful temperaturedifference and will depend on the size and the geometry of therefrigerator. Meaningful temperature differences may be at any number,at increments of 0.1° C. or in the range of 0.1° C.-10° C. In practice,it is likely that values that are multiples of 0.5° C. or 1° C. would bechosen. The temperature difference may be optimised by selecting adistance between the air guide and the edge of the shelf that give thebiggest reduction in temperature difference.

The bottom surface (the “bottom shelf”) of the interior of arefrigerator may be used for displaying produce. However, as such asurface is usually proximate the air inlet, no air guide is usuallyattached to the bottom shelf. Where shelves are mentioned, it should beassumed that the shelf is not the “bottom shelf”, unless explicitlyreferred to.

For refrigerators comprising more than one shelf, an air guide may becoupled to each shelf in the refrigerator. In this case, all of the airguides may be sited at the same distance away from the shelf. In thisscenario, all of the air guides may be moved by the same distance instep (d). Alternatively, each air guide may be sited at a differentdistance away from the respective shelf. In this alternative scenario,the method may be run on a shelf-by-shelf basis, finding a threshold orthe greatest temperature distance for a first shelf and a first airguide, and then performing the method again for a second shelf and asecond air guide and so forth until the air guides have been positionedfor all of the shelves that it is intended to have an air guide coupledto.

In some embodiments, a maximum distance between the air guide and theedge of the shelf is determined, where the maximum distance is thedistance beyond which an average user is obstructed by the air guidefrom viewing an item placed on a shelf sited below the shelf to whichthe air guide is coupled.

An average user is determined by the assumed average height of users ofthe refrigerator, for example shoppers in a grocery store. Such anaverage height may be determined by taking a survey of shoppers in agrocery store. As an example, an average user may be assumed to be 1.75m tall and their eyes may be assumed to be at a height of 1.6 m from theground. On average, it can be assumed that a shopper stands 0.5 m awayfrom a shelf when looking at an item. This distance may change, forexample, if a grocery store has narrow aisles. When looking at a shelf(including the bottom shelf) that is below eye level, the view of a useris likely to be obstructed by an air guide that protrudes excessivelyfrom a shelf that is higher up in the refrigerated interior than theshelf that a user is looking at. Different retailers may have differenttolerances of the percentage of view of a user that can be obstructed.For example, a retailer selling luxury items may wish to accept a lowerenergy efficiency in return for less obstruction of items on lowershelves. A retailer selling broadly identical products may wish tomaximise their energy efficiency in return for more obstruction of itemson lower shelves. For example, an air guide that protrudes further than10 mm from a first shelf can obstruct up to 20% of the view of a user ofa second shelf sited below the first shelf. The maximum distance may,therefore, be set at 10 mm for a refrigerator in the store of a retailerwho is happy to accept an obstruction of up to 20% of the view of a userof a second shelf sited below the first shelf. This may differ from theoptimum distance away from the shelf for energy efficiency, which may,for example, be 20 mm. By limiting the maximum distance between the edgeof the shelf and the air guide, a balance between energy efficiency andallowing a user to view produce on a lower shelf is reached.

A technical advantage of this method is that it helps to avoid the viewof a user from being impeded, whilst still allowing improved energyefficiency associated with installing air guides, and preferably,aerofoils on one or more shelves of a refrigerator.

In some embodiments, the array of temperature sensors are providedwithin the refrigerated storage space. Other locations are discussedbelow. A technical advantage of providing the temperature sensors withinthe refrigerated storage space is that temperature differenceexperienced by items that will be stored in the refrigerator can bemonitored. For example, some meat or dairy products may need to bestored below a certain temperature, by measuring different spots withinthe refrigerated storage space, it is possible to predict whether theseitems can be stored below that temperature at any point in therefrigerator or whether certain shelves should be avoided.

In some embodiments, at least one temperature sensor of the array oftemperature sensors is provided proximate the air inlet. In someembodiments, at least one temperature sensor of the array oftemperatures sensors is provided proximate the air outlet. A technicaladvantage of providing a temperature sensor proximate the air inlet andthe air outlet is that it allows the temperature difference of the aircurtain to be monitored as it flows from the air outlet to the airinlet.

Additionally, at least one temperature sensor of the array oftemperature sensors may be provided in the air duct. The temperaturesensor(s) may be located before and/or after the heat exchanger. Atechnical advantage of providing a temperature sensor in the air duct isthat it allows the amount of cooling imparted by the heat exchanger tobe measured.

In some embodiments, step (f) comprises moving the air guide 10 mm in afirst direction away from the edge of the at least one shelf from thestart point to a first point for a first repetition and moving the airguide 10 mm in the first direction from the first point to a secondpoint for a second repetition.

In some embodiments, step (f) further comprises moving the air guide 10mm in a second direction opposite the first direction from the startpoint.

In some embodiments, the distance between the air guide and the edge ofthe shelf is the minimum distance between a surface of the air guidethat faces the edge of the shelf and the edge of the shelf. The minimumdistance is the shortest physical distance in a straight line betweenthe air guide and the edge of the shelf. When the air guide is anaerofoil, the air guide will comprise a curved surface, hence theminimum distance is the distance measured between the edge of the shelfand the point at which the curve protrudes the most.

In some embodiments, step (f) comprises measuring the distance atregular intervals.

In some embodiments, the air guide may be an aerofoil. An aerofoil worksby being situated in the airflow of the air curtain of the refrigerator,with a portion of the air flow flowing either side of the aerofoil. Theshape of the aerofoil causes a change in the direction of flow of theair curtain as it flows over the aerofoil. An aerofoil comprises apressure surface and a suction surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described with reference to theaccompanying drawings, in which:

FIG. 1 shows method steps for configuring an open display refrigerator.

FIG. 2 shows an average user viewing an item on the shelf of an opendisplay refrigerator.

FIG. 3 shows a bracket for attaching an air guide to a shelf and an airguide attached to the air guide in different positions.

FIGS. 4 a-4 c show a longitudinal section, a cross section and a planview respectively of jelly bricks in an open display refrigerator.

DETAILED DESCRIPTION

FIG. 1 shows a flow chart for a method of configuring an open displayrefrigerator, wherein the open display refrigerator comprises arefrigerated storage space and at least one shelf in the interior of theopen display refrigerator, air in the refrigerated storage space beingseparated from air exterior to the open display refrigerator by an aircurtain established by a fan which blows air towards an air outlet, airin the air curtain being recovered by an air inlet which recirculatesthe air from the air curtain into an air duct coupled to the air outletand wherein the method comprises: providing an array of temperaturesensors within the interior of the open display refrigerator 100;measuring an initial temperature difference between the warmesttemperature recorded by the array of temperature sensors and the coldesttemperature recorded by the array of temperature sensors 101; couplingan air guide to an edge of the at least one shelf distal to a rear wallof the refrigerated storage space at a start point 102; adjusting thedistance between the air guide and the edge of the shelf for the atleast one shelf 103; measuring a final temperature difference associatedwith the distance, the final temperature difference being thetemperature difference between the warmest temperature recorded by thearray of temperature sensors and the coldest temperature recorded by thearray of temperatures sensors after coupling an air guide to the atleast one shelf 104; repeating steps 103 and 104 for a plurality ofdistances at regular intervals 105; selecting a distance from theplurality of distances that gives rise to at least a thresholdtemperature difference, or selecting the distance from the plurality ofdistances wherein the difference between the initial temperaturedifference and the associated final temperature difference is greatest106.

A threshold energy difference might be, for example, a reduction of 1°C. between the warmest and coldest recorded temperatures. Othercharacteristics may be measured, such as energy consumed by therefrigerator with the air guides at different distances. In this case,the method may be changed, so that an initial energy consumption over aset period is measured in step 101. The energy consumed by therefrigerator over a set period is may be measured with the air guide atdifferent distances in step 104. The distance selected in step 106 maybe based on a threshold energy consumption or the greatest difference inenergy consumption. The set period may be, for example, 24 hours or anyamount of time that allows the temperature in the refrigerator tostabilise. The energy consumption may be measured in kWh/24 hr.

In some embodiments, the array of temperature sensors are providedwithin the refrigerated storage space. In some embodiments, atemperature sensor of the array of temperature sensors is providedproximate the air inlet and/or the air outlet. Additionally, at leastone temperature sensor of the array of temperature sensors may beprovided in the air duct. The temperature sensor(s) may be locatedbefore and/or after the heat exchanger.

In some embodiments, the method may include steps that comprisemeasuring the temperature by placing numerous jelly-bricks (examples ofjelly-bricks known in the art are Tylose packs or M-Packs) on theshelves of the refrigerator, wherein each jelly-brick has its owntemperature sensor or probe, which together make up the array oftemperature sensors or probes, so that the temperature at differentpoints of the refrigerator can be tracked. As the location of thewarmest jelly-brick and the location of the coolest jelly-brick maychange with adjustments made to the air guide, the difference betweenthe warmest temperature of the jelly-brick and the coolest temperatureof the jelly-brick may be measured as opposed to measuring thetemperature of the same jelly-bricks before and after adjusting the airguide.

FIG. 2 shows a cross section through an open display refrigerator 200.The refrigerator 200 has a storage space 205 that is maintained at alower than ambient temperature. Within the storage space there are fivestorage shelves 206 a-e. Different embodiments may have one, two, three,four, six or any other reasonable number of storage shelves depending onthe size of the refrigerator. The storage shelves may be flat, may be atan angle or may be a mix of angled and flat shelves. The refrigerator200 establishes an air curtain (not shown) by a fan (not shown) whichblows cold air towards an air outlet 207, out of the air outlet 207 andtowards and air inlet 208. Air inlet 208 recovers air from the aircurtain and a fan 209 within the refrigerator 200 recirculates the airto the air outlet 207. An air guide 203, attached to the shelf 206 dhelps to maintain the path of the air curtain. Air guides may optionallybe attached to one or more of the other shelves 206 a-c, 206 e. The airguide(s) may be in the form of an aerofoil, which works by beingsituated in the airflow of the air curtain of the refrigerator 200, witha portion of the air flow flowing either side of the aerofoil. The shapeof the aerofoil causes a change in the direction of flow of the aircurtain as it flows over the aerofoil. An aerofoil comprises a pressuresurface and a suction surface. A cooling unit or heat exchanger 210within the refrigerator 200 maintains the recirculated air (and hencethe air blown through the air outlet 207 to form the air curtain) at adesired temperature. The desired temperature is chosen to be lower thanambient and acts to prevent cold air in the storage space 205 frommixing with warm air exterior to the refrigerator. An average user 201is shown standing in front of the refrigerator 200, looking at an item204 on a lower shelf 206 e. A portion of the field of view of the user201 that is obstructed by the air guide 203 is shown by the area 202. Ascan be seen in this example, the air guide 203 impedes the user's viewof the item 204, as it protrudes out too far from the edge of the shelf206 d. The method of this application aims to avoid the view of a userfrom being impeded, whilst still allowing improved energy efficiencyassociated with installing aerofoils on one or more shelves of arefrigerator.

FIG. 3 shows a bracket 302 for attaching an air guide to the shelf of arefrigerator (for example, the refrigerator 200 shown in FIG. 2 ). Thebracket allows the air guide 301 to be moved between a number ofdiscrete positions 301 a-d. For example, 301 c might represent a neutralposition for an air guide, 301 d might represent moving the air guidefrom a neutral position closer to the shelf, for example by a distanceof 10 mm (or −10 mm), 301 b might represent moving the air guide from aneutral position away from the shelf, for example by a distance of 10 mm(or +10 mm) and 301 a might represent moving the air guide even furtheraway from the shelf, for example by a distance of 20 mm (or +20 mm).Other discrete intervals are contemplated, for example 5 mm, 7 mm or 15mm. Although the same interval is used in this explanation, a mix ofintervals may be used, for example −4 mm, +6 mm and +9 mm. The positions301 a-301 d may represent the regular intervals of step 105 in FIG. 1 .

FIGS. 4 a-4 c show a longitudinal section, a cross section and a planview of jelly bricks in an open display refrigerator. This is an exampleof how the jelly bricks and the temperature sensors used for measuringthe temperature in the refrigerated storage space may be arranged. Asmentioned previously, numerous jelly-bricks (the jelly-bricks arerepresented by rectangles on the shelves 403 a, b of the refrigerator400 a-c and are indicated by 401 a-c) may be placed on the shelves 403a, b of a refrigerator 400 a-c, where the jelly-bricks 401 a-c emulateitems placed in the refrigerator 400 a-c. The jelly-bricks furthercomprising an “x” (indicated, for example, by 402 a-c) are where thejelly-bricks also comprise a temperature probe for measuring thetemperature difference as indicated in steps 101 and 104 of FIG. 1 .

By repeating steps 103 and 104 of the method, the user will obtain anumber of final temperature differences associated with the selecteddistances between the air guide and the edge of the shelf. Thesetemperature differences can be analysed to see if any of the temperaturedifferences meet a threshold temperature difference or to see which ofthe temperature differences is the greatest. The user can then selectthe distance between the air guide and the edge of the shelf that bestmeets their needs or can repeat steps 103 and 104 again in order tocollect more data points. Once the distance between the air guide andthe edge of the shelf associated with the threshold temperature distanceor the greatest temperature difference is selected, this distance canthen be used to configure the refrigerator. The refrigerator canconfigured by setting the distance between the one or more air guidesand the one or more shelves at the selected distance.

1. A method, comprising: measuring a first energy consumption from aplurality of energy consumptions of a display refrigerator that has anair curtain separating an interior refrigerated space from exterior airwith an air curtain guide that is coupled to an edge of a shelf and in afirst position; adjusting the air guide such that the air guide isspaced apart from the edge of the shelf by each of a plurality ofdistances; measuring remaining energy consumptions from the plurality ofenergy consumptions, each energy consumption from the plurality ofenergy consumptions measured with the air curtain guide spaced apartfrom the edge of the shelf by a different distance from the plurality ofdistances; and selecting a distance from the plurality of distancesbased on that distance being associated with a lowest energy consumptionfrom the plurality of energy consumptions.
 2. The method of claim 1,wherein the shelf is a first shelf, the method further comprising:determining a maximum distance between the air guide and the edge of theshelf, the maximum distance being a distance beyond which the air guideobstructs vision of an average user from viewing an item placed on asecond shelf sited below the first shelf.
 3. The method of claim 1,wherein the air guide is adjusted at 10 mm increments.
 4. The method ofclaim 1, wherein adjusting the air guide includes moving the air guidein a first direction and a second direction opposite the firstdirection.
 5. The method of claim 1, wherein the air guide is coupled tothe edge of the shelf at a minimum distance from the plurality ofdistances.
 6. The method of claim 1, further comprising measuring eachdistance from the plurality of distances while adjusting the air guide.7. The method of claim 1, wherein the air guide is an aerofoil.
 8. Themethod of claim 1, further comprising: measuring an initial energyconsumption; and coupling the air curtain guide to the edge of the shelfafter the initial energy consumption is measured.
 9. The method of claim1, wherein each energy consumption from the plurality of energyconsumptions is measured over a period of 24 hours.
 10. The method ofclaim 1, wherein measuring each energy consumption from the plurality ofenergy consumptions occurs after a temperature within the refrigeratorstabilizes following adjustment of the air guide.
 11. A method,comprising: measuring an initial energy consumption of a displayrefrigerator that has an air curtain separating an interior refrigeratedspace from exterior air; coupling an air curtain guide to an edge of ashelf after measuring the initial energy consumption; adjusting the airguide such that the air guide is spaced apart from the edge of the shelfby each of a plurality of distances; measuring a plurality of energyconsumptions, each energy consumption from the plurality of energyconsumptions measured with the air curtain guide spaced apart from theedge of the shelf by a different distance from the plurality ofdistances; and selecting a distance from the plurality of distancesbased on a difference between (1) the initial energy consumption and (2)an energy consumption from the plurality of energy consumptions that isassociated with that distance being greater than a threshold energydifference.
 12. The method of claim 11, wherein the initial energyconsumption is measured over a period of 24 hours.
 13. The method ofclaim 11, wherein each energy consumption from the plurality of energyconsumptions is measured over a period of 24 hours.
 14. The method ofclaim 11, wherein measuring each energy consumption from the pluralityof energy consumptions occurs after a temperature within therefrigerator stabilizes following adjustment of the air guide.
 15. Themethod of claim 11, wherein the shelf is a first shelf, the methodfurther comprising: determining a maximum distance between the air guideand the edge of the shelf, the maximum distance being a distance beyondwhich the air guide obstructs vision of an average user from viewing anitem placed on a second shelf sited below the first shelf.
 16. Themethod of claim 11, wherein adjusting the air guide includes moving theair guide in a first direction and a second direction opposite the firstdirection.